This nimble, lightweight, extreme terrain master proudly features the groundbreaking TPI (transfer port injection) making it comply with the strict EURO 4 homologation. This means that there is no need for re-jetting or mixing fuel, making this easy-to-shred thoroughbred even simpler to ride and work on while delivering excellent fuel efficiency and clean exhaust emissions. Recognized for its supreme agility, the KTM 150 EXC TPI benefits from a lightweight frame with class-leading flex characteristics that helps elevate rider and machine to incredible new levels of competence.
Thanks to state-of-the-art engineering, innovative 2-stroke design and revolutionary TPI fuel injection technology, the 150 cc 2-stroke powerplant is more refined than ever before, delivering class-leading power throughout the entire rev range. The benefit to this compact, lightweight 2-stroke, is reflected in the highly effective power delivery and easy rideability, making it a great option for those looking to delve into more extreme enduro action. With Euro IV homologation, it’s not only considerately green, but leaves the competition green with envy too.
The KTM 150 EXC TPI cylinder has a bore of 58mm and with the aid of a sophisticated power valve, provides really smooth and controllable power characteristics. For the EFI application the cylinder features two lateral domes which hold the fuel injectors that supply fuel to the rear transfer ports. The downstream injection guarantees excellent atomization of the fuel with the upstreaming air. Thus, the loss of unburnt fuel is minimal, resulting in less emissions, a more efficient combustion and reduced fuel consumption. A small tube in the back of the cylinder is connected with an intake pressure sensor, which supplies pressure data to the control unit. The cylinder features a power valve unit with a sophisticated mechanism for the lateral support exhaust ports. The exhaust port layout increases engine performance, while the upper contour of the exhaust port has been machined to ensure more accurate port timing. The cylinder, with TPI technology, produces outstanding performance over the entire rev range with impressive torque. Last but not least, the cylinder allows for the use of a more widely available traditional type of spark plug.
CRANKCASES & ENGINE COVERS
The compact engine cases are manufactured using a high pressure die-cast production process which helps with weight reduction, while retaining strength and durability. The design allows for optimal shaft arrangements close to the center of gravity, resulting in ideal mass centralization and easier ride-ability. The engine covers feature a smart surface structure which reduces wear caused by the rider’s boots, keeping them looking as fresh as the day you bought your EXC.
The KTM 150 EXC TPI is fitted with a robust 6-speed transmission made by PANKL Racing Systems. The gears are made of a strong, forged raw material, ensuring the highest durability and reliability level. This guarantees superior reliability. Another highlight of the 150 EXC TPI transmission, is the no-dirt gear shifter. Similar to the footpeg design, it prevents the build-up of dirt and ensures the next gear is always available, no matter what the conditions.
ENGINE MANAGEMENT SYSTEM
The engine management system (EMS) of the TPI models features a control unit located below the seat. The ECU defines the ignition timing and amount of fuel to inject is based on several sensor readings such as intake air pressure, throttle position and water temperature plus a new additional ambient air pressure sensor. Thanks to altitude and temperature compensation the rider does not need to worry about fiddling around with the jetting anymore. Should the rider decide to mount a radiator fan from the KTM PowerParts program, it will be controlled directly by the EMS without needing to add an additional thermal switch. An optional map select switch can be purchased, which allows the rider to select an alternate map while on the fly, for the optimal power delivery no matter the conditions.
Say goodbye to numb feet and hands. This engine design allows the implementation of a lateral balancer shaft in order to keep the vibrations to a minimum. You know what that means: more comfort, less fatigue, bigger smiles.
The 150 EXC TPI is fitted with a DS (diaphragm steel) clutch. It features a one-piece clutch basket and primary gear made of high-strength billet steel. Its compact rivet-less design guarantees unbeatable reliability. The clutch is fitted with extremely heat-resistant steel carrier friction discs which ensure excellent disengagement of the clutch and are pre-tensioned by means of a diaphragm spring, substantially reducing the lever force required by the Brembo hydraulic system.
Pre-mixing 2-stroke fuel is a thing of the past for KTM EXC TPI owners. The 2-stroke range is fitted with an oil tank featuring flexible mountings, which greatly improve durability and reliability. In addition, a mesh filter helps prevent dirt getting into the oil pump. Mounted below the oil tank, the oil pump delivers the lubricant directly to the throttle body, where it is mixed with the incoming air to lubricate the piston and crankshaft. Using engine speed and throttle position sensor data, the engine management’s precise electronic control of the oil pump ensures that the ideal amount of oil for any given conditions is used. The filler cap assembly for the oil tank is located between the fuel tank and steering head, utilizing a hose in the upper frame tube to transfer the oil to the storage container. With an average fuel-to-oil ratio of 1:80, the oil capacity of about 0.7 liters is sufficient for at least five tanks of fuel.
The TPI engine is fitted with a 39 mm throttle body made by Dell`Orto. The airflow is regulated by a butterfly connected with a twin-cable throttle cam, which is operated by the handlebar throttle assembly. A throttle position sensor provides airflow data to the control unit. The idle system allows the idle speed to be set more precisely via the bypass screw. Also, the cold start system provides a better supply of extra air when opening a bypass. Oil supplied by the electronically controlled oil pump via an oil intake tube is mixed with the incoming air to lubricate the moving engine parts.
To accommodate the power requirements of the engine management system, the TPI models are fitted with a powerful 196 W alternator and a voltage regulator. The same as can be found on the EXC-F 4-stroke models.
Maintaining the optimal engine temperature is crucial to ensuring consistent horsepower throughout the ride. The KTM 150 EXC TPI features radiators which are mounted close to the center of gravity and match the design of the shrouds perfectly, in order to achieve perfect ergonomics. By using CFD technology (computational fluid dynamics) together with a clever coolant circuit routing, the innovative system ensures the optimum engine temperature for the highest performance, no matter what the conditions. Above all, the delta distributor, integrated into the frame triangle, features a large center tube, making the coolant flow from the cylinder head to the radiators highly efficient. The radiators also feature special protectors that don’t only serve as protection from flying rocks and debris but also as a brace that disperses energy around the radiators in the event of an impact.
When it comes to power delivery and performance, the new exhaust plays a key role and packs a punch that is hard to beat. The pipe is produced with the latest 3-D stamping technology and has an optimized shape. It works perfectly with the TPI engine, producing excellent enduro-specific performance with impressive bottom end power. The silencer features a compact shape and end cap with internal designs individually developed for each model, while it is mounted using an aluminum mounting bracket. In addition, a perforated inner silencer tube works with lighter damping material for efficient and durable noise reduction.
All KTM EXC models feature a high-tech, lightweight chromoly steel frame. This includes hydro-formed elements produced by state-of-the-art robot welding. With its race-proven geometries and optimal stiffness, the frame provides great feedback for the rider, playful handling and remarkable stability. The laterally attached engine head stays (the connection between cylinder, head and frame) are made of aluminum, reducing vibration and further contributing to precise cornering. The bikes also feature lateral frame guards with a structured surface, improving grip, while also serving as a heat protector against the muffler on the right side. The subframe is made of extra-light and stable aluminum profiles, weighing less than 900 gr, providing great rear fender stability.
The KTM 150 EXC TPI’s one-piece aluminum swingarm is manufactured using a gravity die-cast production process, offering exceptional strength at the lowest possible weight. The single-component casting process offers low weight, perfect flex behavior and also allows for a large number of geometry solutions.
KTM uses lightweight, CNC-machined hubs and high-end GIANT rims on all Enduro models, guaranteeing maximum stability and minimum weight. The aluminum spoke nipples feature an innovative design, which conveniently reduces the frequency with which the spokes need to be tightened.
All EXC models are fitted with the latest 48 mm diameter WP XPLOR upside-down forks, featuring a split fork design developed by WP and KTM. While each side is fitted with springs, they have separate damping functions. Compression damping is on the left and the rebound on the right. Both can easily be adjusted via the dials on top of both fork tubes with 30 clicks each. Although already distinguished for outstanding response and damping characteristics, the fork features a calibrated mid-valve piston for consistent damping. The settings keep the front end higher in the stroke, providing impressive reserves against bottoming out.
The WP XPLOR shock absorber is the key element on the proven PDS rear suspension design (progressive damping system), where the shock is directly linked to the swingarm without an additional linkage system. This keeps weight lower and reduces the chances of hooking on rocks. Optimal enduro-specific damping progression is achieved by using a second damping piston in combination with a closed cup towards the end of the stroke, and supported by a progressive shock spring. The settings on the XPLOR PDS shock provide impressive damping characteristics and match the frame and front-end set-up perfectly. It is fully adjustable, including high and low-speed compression, so you can set the shock up to suit any track, trail and rider preferences.
Fitted with forged triple clamps with an offset of 22mm, ensuring a solid grip of the fork and precise handling. The handlebar is adjustable forwards and backwards over 4 positions, so the EXC TPI will fit you like your favorite gloves.
These high-tech Brembo babies are combined with lightweight Wave brake discs. You couldn’t brake any harder or with better feel on an offroad motorcycle.
All models in the EXC range are fitted with lightweight polyethylene tanks improving the ergonomics. The ¼-turn bayonet filler cap makes for quick and easy closure. Manufactured using see-through plastic, you will always be able to see how much fuel remains at a glance. It is fitted with an integrated fuel pump system and a fuel level sensor. Additionally, the fuel line features a 90° connector to the tank for better protection against damage.
The airbox on the KTM 150 EXC TPI ensures optimal flow dynamics, and together with the intake snorkels, results in optimal power and throttle response. Despite the obvious performance enhancements, the design also offers maximum protection against soiling of the air filter. The large twin-Air air filter is mounted on a cleverly designed stiff cage that minimizes incorrect installation. As found on previous models, filter maintenance is quick and easy and does not require tools – a standard, original feature from KTM.
All KTM EXC models are equipped with the same high-strength aluminum tapered handlebar, made by NEKEN. The handlebar allows for four different positions. The handlebars come standard with an ODI vulcanized grip on the right side and a comfortable ODI lock-on grip, which does not require any wire or glue, on the left. Additionally, all models can be equipped with an optional handlebar map select switch, which allows to select between a standard and advanced power curve.
Sophisticated ‘No Dirt’ footpegs prevent smudging up the pegs, even when digging in deep ruts. The pegs on the Enduro models are 6mm higher than the ones used on SX models, which benefits ground clearance. But you can swap them at will.
The EXC range features a lightweight seat that provides great ergonomics and seat comfort thanks to the high foam padding. The seat is conveniently fixed to the bike using one long, lateral screw, making it safe and easy to handle.
The durable in-mold graphics convey the READY TO RACE character of the KTM EXC model line.
BATTERY & WIRING HARNESS
All engines are fitted with the proven electric starter, which is a major benefit for any offroad activity. It is powered by a super lightweight 2 Ah lithium-ion starter battery which provides safe, reliable starting. The wiring harness has most of the electrical components carefully positioned into a common area below the seat, making them more easily accessible and reliable.